US20080014815A1 - Highly filled fibrous veil - Google Patents
Highly filled fibrous veil Download PDFInfo
- Publication number
- US20080014815A1 US20080014815A1 US11/528,102 US52810206A US2008014815A1 US 20080014815 A1 US20080014815 A1 US 20080014815A1 US 52810206 A US52810206 A US 52810206A US 2008014815 A1 US2008014815 A1 US 2008014815A1
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- United States
- Prior art keywords
- fibrous veil
- veil
- impregnated fibrous
- binder
- impregnated
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/38—Inorganic fibres or flakes siliceous
- D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/10—Organic non-cellulose fibres
- D21H13/12—Organic non-cellulose fibres from macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H13/16—Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
- D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
- D21H15/10—Composite fibres
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/36—Polyalkenyalcohols; Polyalkenylethers; Polyalkenylesters
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/63—Inorganic compounds
- D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
- D21H21/52—Additives of definite length or shape
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
Definitions
- the present invention relates to an impregnated fibrous veil particularly characterized by a high filling degree and to a process for manufacturing that veil.
- Fibrous webs or veils of intermingled, randomly oriented reinforcing fibers are well known in the art. Such veils have been used for a number of purposes.
- U.S. Pat. No. 6,497,787 to Geel discloses a process for making a microsphere-filled wet-laid veil useful as a lightweight core reinforcement for GRP sandwich panel applications.
- a formed veil is passed on a belt through a first belt dryer wherein a prebinder is bonded to the nonwoven fibrous veil to form a prebonded nonwoven fibrous veil.
- An impregnation binder liquid including microspheres is then applied to the prebonded nonwoven fibrous veil and subsequently dried in a second dryer.
- the microspheres improve the rigidity or impact resistance of articles reinforced with the resulting microsphere-filled wet-laid veil.
- the present invention relates to an impregnated veil which may be incorporated into cushion vinyl flooring.
- Such flooring includes a polyvinyl chloride top layer, a print layer showing the design, a polyvinyl chloride top foam layer, a polyvinyl chloride saturation layer reinforced with the veil of the present invention and a polyvinyl chloride backing layer (usually a foam).
- the flooring may also include a polyurethane protection layer.
- the impregnated fibrous veil comprises a nonwoven fibrous veil including a prebinder and reinforcing fibers selected from a group consisting of synthetic fibers, glass fibers, ceramic fibers, and mixtures thereof.
- the nonwoven fibrous veil has at least one face impregnated with a surface finish formulation including about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.
- the impregnated fibrous veil may be further characterized by an air porosity of about 100 l/m 2 s to about 2,000 l/m 2 s at 1 m Bar pressure.
- the impregnated fibrous veil has a thickness between about 0.3 mm to about 0.7 mm at 0.5 kPa.
- microspheres are substantially absent from the surface finish formulation.
- the nonwoven fibrous veil includes about 5 to about 20 weight percent prebinder and between about 80 to about 95 weight percent reinforcing fibers.
- the prebinder is typically selected from a group of materials consisting of a water dispersible binder powder or binder fiber.
- the prebinder used may include bonding fibers and typically thermoplastic bonding fibers.
- the prebinder may include bicomponent fibers.
- the reinforcing fibers have a diameter between about 6.5 and about 16 microns and a length between about 4 and about 33 mm.
- the filler utilized in the surface finish formulation is an inorganic filler that is dispersible in water.
- the inorganic filler has an average particle size in the range of between about 0.1 and 50 microns.
- the filler may comprise mineral and/or polymer particles.
- the filler is selected from a group consisting of calcium carbonate, aluminum trihydrate, titanium dioxide, magnesium hydroxide, silicium oxide, clay, talc and mixtures thereof.
- the binder utilized in the surface finish formulation may include both thermosetting and thermoplastic resins.
- the binder is a water dispersible emulsion type binder or a solution type binder.
- the binder may be selected from a group of materials consisting of polymers and copolymers of styrene, butadiene, acrylic, methacrylic monomers, vinyl acetate as well as polyesters, polyvinyl alcohols, melamin formaldehyde resins, urea formaldehyde resins and any mixtures thereof.
- a method of producing an impregnated fibrous veil with a smooth surface finish comprises impregnating at least one face of a nonwoven fibrous veil including a prebinder and reinforcing fibers with a surface finish formulation including about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.
- the impregnating step includes applying the surface finish formulation to at least one face of the nonwoven fibrous veil at a rate of between about 60 g/m 2 to about 200 g/m 2 dry weight.
- the impregnating step further includes feeding the nonwoven fibrous veil in-line during the applying step.
- the impregnating step includes drying and consolidating the impregnated fibrous veil following the applying step.
- FIG. 1 is an edge on elevational view of the impregnated fibrous veil of the present invention.
- FIG. 2 is a schematical representation of the process for making that impregnated fibrous veil.
- the present invention relates to an impregnated fibrous veil 10 including a wet-laid fibrous veil 12 of prebinder and reinforcing fibers having at least one face 14 thereof impregnated with a surface finish formulation 16 .
- That surface finish formulation 16 includes about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.
- wet-laid fibrous veil refers to a web of intermingled, randomly oriented reinforcing fibers made according to a wet-laid process.
- the “veil” of the present invention may also include “sheets” or “mats” made in accordance with the wet-laid process.
- the fibers are preferably segmented and optionally, the formed veil may be reinforced with continuous filaments.
- “Impregnating” or “impregnated” as used herein refers to a means of integrating fillers into the fibrous veil.
- the method of impregnating may be conducted by any method suitable for integrating or incorporating these materials into the fibrous veil.
- the fillers are impregnated into the veil at any time after formation of the veil.
- the fillers are preferably impregnated after formation in a formation chamber, such as on a wire, or after being passed through a first dryer.
- the impregnated fibrous veil 10 of the present invention comprises a nonwoven wet-laid fibrous veil 12 including a prebinder and reinforcing fibers selected from a group consisting of glass fibers, ceramic fibers, synthetic fibers and mixtures thereof. More specifically, the nonwoven fibrous veil 12 includes about 5 to about 25 weight percent prebinder and between about 75 to about 95 weight percent reinforcing fibers. More typically, the veil 12 includes about 10 to about 20 weight percent prebinder and between about 80 to about 90 weight percent reinforcing fibers.
- the prebinder can consist of bonding powder or includes bonding fibers and preferably thermoplastic bonding fibers. The prebinder may also include bicomponent fibers.
- the reinforcing fibers typically have a diameter between about 6.5 and about 16 microns and a length between about 4 and about 33 mm.
- At least one face 14 of the nonwoven fibrous veil 12 is impregnated with a surface finish formulation 16 .
- That surface finish formulation includes about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.
- the filler is an inorganic or mineral filler and/or polymer particle that is dispersible in water.
- the average particle size is less than 50 microns and preferably below 30 microns. In order to ensure good surface quality and smoothness, a typical particle size distribution range is from about 0.1 to about 10.0 microns with an average of 5 microns.
- Fillers useful in the present invention include but are not limited to calcium carbonate, aluminum trihydrate, titanium dioxide, magnesium hydroxide, silicium oxide, clay, talc, recycled glass fibers, recycled glass veil and mixtures thereof.
- the binder of the surface finish formulation may include both thermosetting and thermoplastic resins.
- the binder is a water dispersible emulsion type binder.
- it may be a solution type binder.
- Binders useful in the surface finish formulation 16 include but are not limited to polymers and copolymers of styrene, butadiene, acrylic and methacrylic monomers, vinyl acetate as well as polyesters, polyvinyl alcohols, melamin formaldehyde resins, urea formaldehyde reins and any mixtures thereof.
- the binder may include both a solution type binder and an emulsion type binder provided at a ratio of between about 0.1 to 1 to about 10 to 1.
- a useful binder is a combination of polyvinyl alcohol and acrylic emulsion at a ratio of about 1 to 2.
- the optional optical brightener useful in the surface finish formulation 16 is preferably a water dispersible optical brightener that is not sensitive to degradation due to weathering. Thus, the optical brightener must, for example, be resistant to ultraviolet radiation of the sun.
- An example of an appropriate optical brightener useful in the highly filled formulation 16 is Leucophor UO as manufactured and sold by Clariant Benelux.
- the process of manufacturing the impregnated fibrous veil 10 of the present invention is illustrated in FIG. 2 .
- the prebinder, reinforcing fibers and water are agitated in a mixing tank 50 to provide an aqueous fiber slurry.
- the reinforcing fibers may be used as filaments or as strands of gathered filaments in chopped form.
- to continuous filaments can be used as length-oriented reinforcement for the veil.
- Additional elements to make up the aqueous slurry may be added as is known in the art. For example, surfactants, anti-foams, viscosity modifier and anti-microbial agents may be provided along with the prebinder into the slurry.
- the aqueous fiber slurry is transferred from the mixing tank 50 onto a suitable forming apparatus 52 .
- the forming apparatus may, for example, take the form of a moving screen or forming wire on an inclined wire forming machine, wire cylinders, Foudrinier machines, Stevens Former, Roto Former, Inver Former or Venti Former machines.
- the formation of the veil 12 is on an inclined wire forming machine.
- the fibers and the additional slurry elements in the aqueous fiber slurry enmesh themselves into a freshly prepared wet laid fibrous veil 12 on the forming apparatus 52 while excess water is separated therefrom.
- the dewatering step may be conducted by any known method such as by draining, vacuum, etc.
- the water content of the veil after dewatering and vacuum is preferably in the range of about 50 to about 85%.
- the veil is transferred to a transport belt 54 .
- the belt 54 carries the veil 12 into a means 56 for substantially removing the water.
- the removal of water may be conducted by known web drying methods, including the use of a rotary/through air dryer or oven, a heated drum dryer, an infrared heating source, hot air blowers, microwave emitting source and the like. At least one method of drying is necessary for removing the water but a plurality of these methods may be used in combination to remove the water and dry the wet laid fibrous veil 12 .
- the temperature of the dryer may range from about 120 degrees C. at the start until about 210 degrees C. at the end of the first drying process.
- the air speed may be in the range of about 0.5 to 1 m/s.
- the prebinder is bound to the reinforcing fibers in order to prebond the veil 12 .
- the prebonded veil 12 is then impregnated with the highly filled formulation 16 by applying the surface finish formulation at a dry rate of between about 60 g/m 2 to about 200 g/m 2 .
- Any method suitable for impregnating at least one face 14 of the prebonded veil 12 may be used.
- suitable methods include using a size press 58 , such as a Foulard applicator, a binder wire, rotary screen, dipping roll, spraying, coating equipment and the like. While other additional agents or coatings may be applied, preferably only the surface finish formulation 16 is contacted with the prebonded veil 12 .
- the drying and consolidating of the impregnated fibrous veil 10 is the now impregnated veil 10 is dried in a second dryer 60 which is preferably an airfloat oven.
- the resulting dried impregnated fibrous veil 10 is then collected on a winder 62 .
- the veil 10 of the present invention may be used as a carrier to manufacture cushion vinyl flooring.
- such flooring incorporating the impregnated fibrous veil 10 of the present invention exhibits a number of beneficial properties including reduced plastisol consumption and improved stiffness. Additionally, the panels provide better environmental durability.
- a base veil consisting of 50 gsm weight made of 84% glass fiber and 16% PVA binder is impregnated with 170 gsm binder consisting of ⁇ 95% anorganic powder and ⁇ 5% polymeric binder.
- a base veil consisting of 35 gsm weight made of 84% glass fiber and 16% PVA binder is impregnated with 125 gsm binder consisting of ⁇ 95% anorganic powder and ⁇ 5% polymeric binder.
- a base veil consisting of 30 gsm weight made of 84% glass fiber and 16% PVA binder is impregnated with 95 gsm binder consisting of ⁇ 95% anorganic powder and ⁇ 5% polymeric binder.
- the impregnated fibrous veil 10 of the present invention is characterized by a unique combination of properties.
- the veil 10 has an air porosity of between about 100 l/m 2 s to about 2,000 l/m 2 s at 1 m Bar pressure. This allows good wet out of the surface veil with resin. Further, the veil 10 has a thickness of about 0.3 mm to about 0.7 mm at 0.5 kPa. The veil 10 is thin but retains good print through hiding power.
- the prebinder and reinforcing fibers are heat cured prior to application of the surface finish formulation.
- the surface finish formulation may be applied to the nonwoven fibrous veil including the prebinder and reinforcing fibers prior to curing of the prebinder. In this way both the prebinder and surface finish formulation are cured simultaneously during a single heating step.
- the surface finish formulation is applied inline to the prebonded fibrous veil, it does not have to be.
- the process as illustrated in FIG. 2 relates to the application of the surface finish formulation to only one face 14 of the veil 12 , it should be appreciated that it may be applied to both, opposing faces.
- the veil 12 may be brought into the Foulard applicator to assure that the prebonded veil 12 is wetted on both sides. This may be done by bringing the veil into the applicator from above in a double roll system, wherein surface finish formulation is capable of coating both sides/faces of the veil.
- the impregnated veil 10 is dried and/or cured in an oven or other drying device.
Abstract
Description
- The present invention relates to an impregnated fibrous veil particularly characterized by a high filling degree and to a process for manufacturing that veil.
- Fibrous webs or veils of intermingled, randomly oriented reinforcing fibers are well known in the art. Such veils have been used for a number of purposes.
- For example, U.S. Pat. No. 6,497,787 to Geel discloses a process for making a microsphere-filled wet-laid veil useful as a lightweight core reinforcement for GRP sandwich panel applications. In this process a formed veil is passed on a belt through a first belt dryer wherein a prebinder is bonded to the nonwoven fibrous veil to form a prebonded nonwoven fibrous veil. An impregnation binder liquid including microspheres is then applied to the prebonded nonwoven fibrous veil and subsequently dried in a second dryer. The microspheres improve the rigidity or impact resistance of articles reinforced with the resulting microsphere-filled wet-laid veil.
- The present invention relates to an impregnated veil which may be incorporated into cushion vinyl flooring. Such flooring includes a polyvinyl chloride top layer, a print layer showing the design, a polyvinyl chloride top foam layer, a polyvinyl chloride saturation layer reinforced with the veil of the present invention and a polyvinyl chloride backing layer (usually a foam). The flooring may also include a polyurethane protection layer.
- An impregnated fibrous veil is disclosed. The impregnated fibrous veil comprises a nonwoven fibrous veil including a prebinder and reinforcing fibers selected from a group consisting of synthetic fibers, glass fibers, ceramic fibers, and mixtures thereof. The nonwoven fibrous veil has at least one face impregnated with a surface finish formulation including about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.
- Still more specifically describing the invention the impregnated fibrous veil may be further characterized by an air porosity of about 100 l/m2s to about 2,000 l/m2s at 1 m Bar pressure. The impregnated fibrous veil has a thickness between about 0.3 mm to about 0.7 mm at 0.5 kPa.
- Additionally, it should be appreciated that microspheres are substantially absent from the surface finish formulation.
- The nonwoven fibrous veil includes about 5 to about 20 weight percent prebinder and between about 80 to about 95 weight percent reinforcing fibers. The prebinder is typically selected from a group of materials consisting of a water dispersible binder powder or binder fiber. The prebinder used may include bonding fibers and typically thermoplastic bonding fibers. The prebinder may include bicomponent fibers. The reinforcing fibers have a diameter between about 6.5 and about 16 microns and a length between about 4 and about 33 mm.
- The filler utilized in the surface finish formulation is an inorganic filler that is dispersible in water. The inorganic filler has an average particle size in the range of between about 0.1 and 50 microns. The filler may comprise mineral and/or polymer particles. Typically the filler is selected from a group consisting of calcium carbonate, aluminum trihydrate, titanium dioxide, magnesium hydroxide, silicium oxide, clay, talc and mixtures thereof.
- The binder utilized in the surface finish formulation may include both thermosetting and thermoplastic resins. Typically the binder is a water dispersible emulsion type binder or a solution type binder. The binder may be selected from a group of materials consisting of polymers and copolymers of styrene, butadiene, acrylic, methacrylic monomers, vinyl acetate as well as polyesters, polyvinyl alcohols, melamin formaldehyde resins, urea formaldehyde resins and any mixtures thereof.
- In accordance with yet another aspect of the present invention, a method of producing an impregnated fibrous veil with a smooth surface finish is provided. The method comprises impregnating at least one face of a nonwoven fibrous veil including a prebinder and reinforcing fibers with a surface finish formulation including about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.
- The impregnating step includes applying the surface finish formulation to at least one face of the nonwoven fibrous veil at a rate of between about 60 g/m2 to about 200 g/m2 dry weight. The impregnating step further includes feeding the nonwoven fibrous veil in-line during the applying step. Still further the impregnating step includes drying and consolidating the impregnated fibrous veil following the applying step.
- In the following description there is shown and described a preferred embodiment of this invention simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
- The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain certain principles of the invention. In the drawings:
-
FIG. 1 is an edge on elevational view of the impregnated fibrous veil of the present invention; and -
FIG. 2 is a schematical representation of the process for making that impregnated fibrous veil. - Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.
- The present invention relates to an impregnated
fibrous veil 10 including a wet-laidfibrous veil 12 of prebinder and reinforcing fibers having at least oneface 14 thereof impregnated with asurface finish formulation 16. Thatsurface finish formulation 16 includes about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener. - As used herein, the term “wet-laid fibrous veil” refers to a web of intermingled, randomly oriented reinforcing fibers made according to a wet-laid process. The “veil” of the present invention may also include “sheets” or “mats” made in accordance with the wet-laid process. The fibers are preferably segmented and optionally, the formed veil may be reinforced with continuous filaments.
- “Impregnating” or “impregnated” as used herein, refers to a means of integrating fillers into the fibrous veil. The method of impregnating may be conducted by any method suitable for integrating or incorporating these materials into the fibrous veil. In accordance with the present invention, the fillers are impregnated into the veil at any time after formation of the veil. In particular, the fillers are preferably impregnated after formation in a formation chamber, such as on a wire, or after being passed through a first dryer.
- As previously noted, the impregnated
fibrous veil 10 of the present invention comprises a nonwoven wet-laidfibrous veil 12 including a prebinder and reinforcing fibers selected from a group consisting of glass fibers, ceramic fibers, synthetic fibers and mixtures thereof. More specifically, the nonwovenfibrous veil 12 includes about 5 to about 25 weight percent prebinder and between about 75 to about 95 weight percent reinforcing fibers. More typically, theveil 12 includes about 10 to about 20 weight percent prebinder and between about 80 to about 90 weight percent reinforcing fibers. The prebinder can consist of bonding powder or includes bonding fibers and preferably thermoplastic bonding fibers. The prebinder may also include bicomponent fibers. The reinforcing fibers typically have a diameter between about 6.5 and about 16 microns and a length between about 4 and about 33 mm. - At least one
face 14 of the nonwovenfibrous veil 12 is impregnated with asurface finish formulation 16. That surface finish formulation includes about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener. Typically the filler is an inorganic or mineral filler and/or polymer particle that is dispersible in water. The average particle size is less than 50 microns and preferably below 30 microns. In order to ensure good surface quality and smoothness, a typical particle size distribution range is from about 0.1 to about 10.0 microns with an average of 5 microns. Fillers useful in the present invention include but are not limited to calcium carbonate, aluminum trihydrate, titanium dioxide, magnesium hydroxide, silicium oxide, clay, talc, recycled glass fibers, recycled glass veil and mixtures thereof. - The binder of the surface finish formulation may include both thermosetting and thermoplastic resins. Typically the binder is a water dispersible emulsion type binder. Alternatively, it may be a solution type binder. Binders useful in the
surface finish formulation 16 include but are not limited to polymers and copolymers of styrene, butadiene, acrylic and methacrylic monomers, vinyl acetate as well as polyesters, polyvinyl alcohols, melamin formaldehyde resins, urea formaldehyde reins and any mixtures thereof. The binder may include both a solution type binder and an emulsion type binder provided at a ratio of between about 0.1 to 1 to about 10 to 1. A useful binder is a combination of polyvinyl alcohol and acrylic emulsion at a ratio of about 1 to 2. - The optional optical brightener useful in the
surface finish formulation 16 is preferably a water dispersible optical brightener that is not sensitive to degradation due to weathering. Thus, the optical brightener must, for example, be resistant to ultraviolet radiation of the sun. An example of an appropriate optical brightener useful in the highly filledformulation 16 is Leucophor UO as manufactured and sold by Clariant Benelux. - The process of manufacturing the impregnated
fibrous veil 10 of the present invention is illustrated inFIG. 2 . In the illustrated wet lay process, the prebinder, reinforcing fibers and water are agitated in amixing tank 50 to provide an aqueous fiber slurry. The reinforcing fibers may be used as filaments or as strands of gathered filaments in chopped form. Optionally, to continuous filaments can be used as length-oriented reinforcement for the veil. Additional elements to make up the aqueous slurry may be added as is known in the art. For example, surfactants, anti-foams, viscosity modifier and anti-microbial agents may be provided along with the prebinder into the slurry. - As illustrated in
FIG. 2 the aqueous fiber slurry is transferred from the mixingtank 50 onto a suitable formingapparatus 52. The forming apparatus may, for example, take the form of a moving screen or forming wire on an inclined wire forming machine, wire cylinders, Foudrinier machines, Stevens Former, Roto Former, Inver Former or Venti Former machines. Preferably, the formation of theveil 12 is on an inclined wire forming machine. The fibers and the additional slurry elements in the aqueous fiber slurry enmesh themselves into a freshly prepared wet laidfibrous veil 12 on the formingapparatus 52 while excess water is separated therefrom. The dewatering step may be conducted by any known method such as by draining, vacuum, etc. The water content of the veil after dewatering and vacuum is preferably in the range of about 50 to about 85%. - After the wet-laid nonwoven
fibrous veil 12 is formed, the veil is transferred to atransport belt 54. Thebelt 54 carries theveil 12 into ameans 56 for substantially removing the water. The removal of water may be conducted by known web drying methods, including the use of a rotary/through air dryer or oven, a heated drum dryer, an infrared heating source, hot air blowers, microwave emitting source and the like. At least one method of drying is necessary for removing the water but a plurality of these methods may be used in combination to remove the water and dry the wet laidfibrous veil 12. The temperature of the dryer may range from about 120 degrees C. at the start until about 210 degrees C. at the end of the first drying process. The air speed may be in the range of about 0.5 to 1 m/s. During drying the prebinder is bound to the reinforcing fibers in order to prebond theveil 12. - The
prebonded veil 12 is then impregnated with the highly filledformulation 16 by applying the surface finish formulation at a dry rate of between about 60 g/m2 to about 200 g/m2. Any method suitable for impregnating at least oneface 14 of theprebonded veil 12 may be used. For example, suitable methods include using asize press 58, such as a Foulard applicator, a binder wire, rotary screen, dipping roll, spraying, coating equipment and the like. While other additional agents or coatings may be applied, preferably only thesurface finish formulation 16 is contacted with theprebonded veil 12. Following the impregnation of theface 14 of theprebonded veil 12 with thesurface finish formulation 16, is the drying and consolidating of the impregnatedfibrous veil 10. Thus the now impregnatedveil 10 is dried in asecond dryer 60 which is preferably an airfloat oven. The resulting dried impregnatedfibrous veil 10 is then collected on awinder 62. - The
veil 10 of the present invention may be used as a carrier to manufacture cushion vinyl flooring. Advantageously, such flooring incorporating the impregnatedfibrous veil 10 of the present invention exhibits a number of beneficial properties including reduced plastisol consumption and improved stiffness. Additionally, the panels provide better environmental durability. - The following examples are presented in order to further illustrate the invention, but is not to be considered as limited thereto.
- A base veil consisting of 50 gsm weight made of 84% glass fiber and 16% PVA binder is impregnated with 170 gsm binder consisting of ˜95% anorganic powder and ˜5% polymeric binder.
- A base veil consisting of 35 gsm weight made of 84% glass fiber and 16% PVA binder is impregnated with 125 gsm binder consisting of ˜95% anorganic powder and ˜5% polymeric binder.
- A base veil consisting of 30 gsm weight made of 84% glass fiber and 16% PVA binder is impregnated with 95 gsm binder consisting of ˜95% anorganic powder and ˜5% polymeric binder.
- The impregnated
fibrous veil 10 of the present invention is characterized by a unique combination of properties. Theveil 10 has an air porosity of between about 100 l/m2s to about 2,000 l/m2s at 1 m Bar pressure. This allows good wet out of the surface veil with resin. Further, theveil 10 has a thickness of about 0.3 mm to about 0.7 mm at 0.5 kPa. Theveil 10 is thin but retains good print through hiding power. - The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, in accordance with the method illustrated in
FIG. 2 , the prebinder and reinforcing fibers are heat cured prior to application of the surface finish formulation. It should be appreciated, however, that the surface finish formulation may be applied to the nonwoven fibrous veil including the prebinder and reinforcing fibers prior to curing of the prebinder. In this way both the prebinder and surface finish formulation are cured simultaneously during a single heating step. - In addition, while it is preferred that the surface finish formulation is applied inline to the prebonded fibrous veil, it does not have to be. Further, while the process as illustrated in
FIG. 2 relates to the application of the surface finish formulation to only oneface 14 of theveil 12, it should be appreciated that it may be applied to both, opposing faces. Thus, theveil 12 may be brought into the Foulard applicator to assure that theprebonded veil 12 is wetted on both sides. This may be done by bringing the veil into the applicator from above in a double roll system, wherein surface finish formulation is capable of coating both sides/faces of the veil. Subsequently, the impregnatedveil 10 is dried and/or cured in an oven or other drying device. - The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
Claims (24)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/528,102 US20080014815A1 (en) | 2006-07-13 | 2006-09-27 | Highly filled fibrous veil |
EP07810464A EP2076623A1 (en) | 2006-09-27 | 2007-07-12 | Highly filled fibrous veil |
CA002663681A CA2663681A1 (en) | 2006-09-27 | 2007-07-12 | Highly filled fibrous veil |
PCT/US2007/016026 WO2008039262A1 (en) | 2006-09-27 | 2007-07-12 | Highly filled fibrous veil |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/485,652 US20080014814A1 (en) | 2006-07-13 | 2006-07-13 | Highly filled fibrous veil |
US11/528,102 US20080014815A1 (en) | 2006-07-13 | 2006-09-27 | Highly filled fibrous veil |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/485,652 Continuation-In-Part US20080014814A1 (en) | 2004-06-18 | 2006-07-13 | Highly filled fibrous veil |
Publications (1)
Publication Number | Publication Date |
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US20080014815A1 true US20080014815A1 (en) | 2008-01-17 |
Family
ID=38875005
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/528,102 Abandoned US20080014815A1 (en) | 2006-07-13 | 2006-09-27 | Highly filled fibrous veil |
Country Status (4)
Country | Link |
---|---|
US (1) | US20080014815A1 (en) |
EP (1) | EP2076623A1 (en) |
CA (1) | CA2663681A1 (en) |
WO (1) | WO2008039262A1 (en) |
Cited By (6)
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US20090253323A1 (en) * | 2008-04-03 | 2009-10-08 | Usg Interiors, Inc. | Non-woven material and method of making such material |
US20100143684A1 (en) * | 2004-06-18 | 2010-06-10 | Owens Corning | Fibrous veil impregnated with surface finish formulation |
US20130342489A1 (en) * | 2008-08-13 | 2013-12-26 | Michael R. Feldman | Multimedia, multiuser system and associated methods |
EP2985374A1 (en) * | 2014-08-14 | 2016-02-17 | Johns Manville Europe GmbH | Method for the production of high-filled non-woven fabrics |
US20210115603A1 (en) * | 2018-06-05 | 2021-04-22 | Saint-Gobain Adfors | Textile structure based on glass fibers for acoustic ceiling or acoustic wall panel |
US20220251779A1 (en) * | 2019-06-13 | 2022-08-11 | Owens Corning Intellectual Capital, Llc | Walkable facer mats for roof insulation |
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Publication number | Priority date | Publication date | Assignee | Title |
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RU2016118988A (en) * | 2013-10-18 | 2017-11-24 | Бонар Б.В. | Vinyl floor covering |
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US20220251779A1 (en) * | 2019-06-13 | 2022-08-11 | Owens Corning Intellectual Capital, Llc | Walkable facer mats for roof insulation |
Also Published As
Publication number | Publication date |
---|---|
CA2663681A1 (en) | 2008-04-03 |
EP2076623A1 (en) | 2009-07-08 |
WO2008039262A1 (en) | 2008-04-03 |
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